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Old April 23rd, 2013, 03:19 PM   #1
marines2060
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1986 ninja 250 build

Hey all, ive been around here for awhile now, thought id start a build thread!

Short story: I got this bike for free i wanna fix it and ride it this summer.

Long story: I got the chance to pick this bike up about two years ago from a good friend who had kept it for 10 years without touching it. It had a blown motor and tons of pieces missing, mostly trim. I was big into bikes right out of high school, well things happened and i have to move out on my own and the bike was in storage till this past weekend when i got it back into a garage! I worked on it for a few months before i had to move out, i found some rough front fairings and little odds and ends, swapped the motor out from an eliminator 250 and ran into an electrical problem that i will still need help to diagnose. I snagged a NOS windshield on ebay which is awesome. Theres also no title to it as of now, I will have to deal with that at the dmv. I plan to take the saftey course in between spring semester ending and summer school starting.

some pictures...









This looks like the right place to post a build thread, if not please move it to the right place.

I am new to motorcycles but not to wrenching. My job specializes in renting, preping, and track side service for Ford Spec Racers. its an awesome job that i have been doing for a year almost.

some pictures of that...





Im also big into bmw's My daily is a 1990 325is and im also building a 1970 2002 that will be for the track. I will be busy with these too, so this will be painfully slow but ill try my best to not make you guys fall asleep.

some of that....





My plan for the bike is to first get it to run and then work on cosmetics/ upgrades and ride it any chance i get! Ill be asking a lot of noob questions so bare with me.

thanks,

Tony
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Old April 23rd, 2013, 03:21 PM   #2
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Old April 23rd, 2013, 03:54 PM   #3
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That's awesome what you do! I am envious of your job I love wrenching and this is pretty much my dream job. I am honestly more of a Mazda guy i love the wankel rotaries. But with the blown up engine were the cams good?
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Old April 23rd, 2013, 03:54 PM   #4
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I would buy them off ya.
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Old April 23rd, 2013, 04:06 PM   #5
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Tony, welcome to the carnival. Do you own those Fords and rent them or just wrench on them. I'd love to give one a buzz around a track. Looks like fun!
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Old April 23rd, 2013, 04:28 PM   #6
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Quote:
Originally Posted by quarterliter View Post
That's awesome what you do! I am envious of your job I love wrenching and this is pretty much my dream job. I am honestly more of a Mazda guy i love the wankel rotaries. But with the blown up engine were the cams good?
It is an awesome job man, its great going to the track and watching what you prepped racing with others.

The cams were no good. Bummer i know.

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Tony, welcome to the carnival. Do you own those Fords and rent them or just wrench on them. I'd love to give one a buzz around a track. Looks like fun!
I dont own them. I work for HSE racing as the head crew chief. my boss owns two of them that he rents out for an arrive and drive type deal. you bring your helmet and race suit and we take care of the rest. Fuel, service, data, ect. There are others cars at the shop that people own that we work on and provide track side service and hauling. they are awesome. just 1.9 escourt engines but only weigh 1670lbs with driver usually so high corner speeds.
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Old April 23rd, 2013, 04:51 PM   #7
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I like the design of that Ninja over the most common "pregen" model which I believe is the 88-07 models. Heck it's even got a two piece seat! except the front seat is like half of the gas tank lol. Cool bike though definitely gonna keep an eye on this thread
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Old April 23rd, 2013, 04:55 PM   #8
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I'm hoping one day to get a mechanical engineering degree and work for some motorcycle manufacturer doing rnd for their race team. But yea bummer cams are toast
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Old April 23rd, 2013, 04:58 PM   #9
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Quote:
Originally Posted by marines2060 View Post


I dont own them. I work for HSE racing as the head crew chief. my boss owns two of them that he rents out for an arrive and drive type deal. you bring your helmet and race suit and we take care of the rest. Fuel, service, data, ect. There are others cars at the shop that people own that we work on and provide track side service and hauling. they are awesome. just 1.9 escourt engines but only weigh 1670lbs with driver usually so high corner speeds.
What is the cost of rental and what tracks?
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Old April 23rd, 2013, 06:12 PM   #10
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Tony.. Your a man of many projects.. Lol ... I fall into that category as well ... I really like the look of the first gen 250's .. That Beemer should be hella fun too.. Getting a title on these bikes isn't hard if you have an issue locally there are other options for you I got mine titled for 74 dollArs ... Shoot me a pm and I can let ya in on a loophole I know of to get the older bikes titled
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Old April 23rd, 2013, 08:08 PM   #11
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Quote:
Originally Posted by KawiKid860 View Post
I like the design of that Ninja over the most common "pregen" model which I believe is the 88-07 models. Heck it's even got a two piece seat! except the front seat is like half of the gas tank lol. Cool bike though definitely gonna keep an eye on this thread
thanks man, i hope i dont disappoint.

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I'm hoping one day to get a mechanical engineering degree and work for some motorcycle manufacturer doing rnd for their race team. But yea bummer cams are toast
You and me are the same, im currently trying to get mine at santa clara university. Its hard work. i have 3 more years to go and have already done 3 at a community college.

Quote:
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What is the cost of rental and what tracks?
I have a number in my head, but let me double check for you. We usually do thunder hill, laguna seca, and infineon mostly, this coming weekend we are going to buttonwillow, though thats only for a national race.


Quote:
Originally Posted by Rollingmenace View Post
Tony.. Your a man of many projects.. Lol ... I fall into that category as well ... I really like the look of the first gen 250's .. That Beemer should be hella fun too.. Getting a title on these bikes isn't hard if you have an issue locally there are other options for you I got mine titled for 74 dollArs ... Shoot me a pm and I can let ya in on a loophole I know of to get the older bikes titled
Me too, they are way better looking than the 88-07 but hard to find some specific parts. I haven't looked to deep into getting a title but i will forsure pm you if i have any troubles, thanks ahead of time.
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Old April 23rd, 2013, 09:36 PM   #12
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I have 2 more to go on my ME degree. I've given up on trying to do something cool and have accepted the cruel reality that most ME's just end up in manufacturing. I'll leave the fun time for my private projects, not my work.
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Old April 23rd, 2013, 09:39 PM   #13
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Are those the stock handlebars? I never looked too closely at them on other 86/87 250E models.
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Old April 23rd, 2013, 09:39 PM   #14
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What is the cost of rental and what tracks?
Boss said "800 a day (which i was thinking) if you like them and 1000 if you dont" that includes towing too.
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Old April 23rd, 2013, 09:42 PM   #15
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didn't get much done tonight due to school, but i got the stand up and batt on the charger, hopefully it has some life, also got another box of stuff from storage. In it are little things hardware, brake pads, seat covers ect...







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Old April 23rd, 2013, 11:21 PM   #16
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Are those the stock handlebars? I never looked too closely at them on other 86/87 250E models.
they are stock, the handlebar risers on a 1986-87 are not as tall and point more outwards than the 88 and up models i dont think they are interchangeable.
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Old April 24th, 2013, 06:01 AM   #17
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Rebuild projects are the best. I will be watching this.
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Old April 24th, 2013, 06:10 AM   #18
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Congrats on getting started on the rebuild/restoration, sometimes just getting started is the hardest part, keep us updated on your progress.
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Old April 24th, 2013, 10:42 AM   #19
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I'm hoping that I'll find something that I enjoy doing for a job. Mainly engine development.
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Old April 24th, 2013, 10:45 AM   #20
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I have to wounded how many of those are left. The 86-87 is a different bike then the first gen. Would that be called a pre gen?
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Old April 24th, 2013, 03:31 PM   #21
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they are stock, the handlebar risers on a 1986-87 are not as tall and point more outwards than the 88 and up models i dont think they are interchangeable.
I like 'em. Are the forks 36mm? If so, I wonder if the whole top triple clamp will swap with them.
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Old April 24th, 2013, 03:41 PM   #22
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I have to wounded how many of those are left. The 86-87 is a different bike then the first gen. Would that be called a pre gen?
"pregen" means previous generation. They are no longer the previous generation, so: No.

Technically, the EX250L is the current generation so now the 2008-2012 bikes are "pregen."

That's why I suggest we move away from using that designation. 86/87 is E-gen (EX250E).

What we formerly called "pregen" is now is 250F, F-bike, F-gen, or whatever.
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Old April 24th, 2013, 04:02 PM   #23
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"pregen" means previous generation. They are no longer the previous generation, so: No.

Technically, the EX250L is the current generation so now the 2008-2012 bikes are "pregen."

That's why I suggest we move away from using that designation. 86/87 is E-gen (EX250E).

What we formerly called "pregen" is now is 250F, F-bike, F-gen, or whatever.
makes sense....

Awesome bike! I hope to see it on one of the local group rides some day.
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Old April 26th, 2013, 07:05 PM   #24
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today i had a little time to work on the bike. Stripped the body work off of it and piled it up for a day when i want to do fiberglass work. I drained the old gas thats been sitting for 2 years. The battery still has life left in it, then i tried to sort out the electrical problem i had before i got my hands on it again.

Last time i worked on it wasn't getting spark on one of the spark plugs, so i started there. I saw that when the bike was in the "on" position, the side where i was getting spark i was getting ~9.75v from the wiring going to the coil. On the other side where i wasn't getting spark, the wiring going into the coil was 0v nothing at all. I traced the wiring to see if something was pinched or not connected right and found nothing. The power and ground both go to the igniter, do those go bad often? If im getting power to the other coil does that mean its not the igniter since they are both coming from that? what else is there that i didn't check? or did none of that make any sense, haha.

pictures anyways!



naked 250





stuff i need to fix/prep for paint

Thanks!
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Old April 26th, 2013, 07:12 PM   #25
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I like 'em. Are the forks 36mm? If so, I wonder if the whole top triple clamp will swap with them.
im pretty sure the manual says 1.42 inches so thats 36mm, i dont know if the whole top would swap, that would be sweet though.
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Old April 27th, 2013, 03:57 AM   #26
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I f memory serves, you should have battery voltage at one side of the coil and the igniter ( CDI ) box should toggle the other side. That's if it's a 2 wire coil. If the ignition is on and the bike is not running one side will have battery voltage and the other side will have about the same.
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Old April 27th, 2013, 10:38 PM   #27
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I f memory serves, you should have battery voltage at one side of the coil and the igniter ( CDI ) box should toggle the other side. That's if it's a 2 wire coil. If the ignition is on and the bike is not running one side will have battery voltage and the other side will have about the same.
Thanks for the input Bruce, I will try to look into it more tomorrow hopefully.

any other suggestions?

Last futzed with by marines2060; April 28th, 2013 at 10:49 AM.
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Old May 5th, 2013, 05:36 AM   #28
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el250 engine

Did you swap over the 1986-1987 EX250E stator rotor onto the EL250 engine?

You need to and also use its two pulsing coil pickups instead of the newer single coil pickup (found on the EL250B/E and EX250F's) if you are using the analog 1986-1987 igniter.


Nice to see another of these early model being saved. I got two of them myself.
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Old May 5th, 2013, 09:37 AM   #29
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Did you swap over the 1986-1987 EX250E stator rotor onto the EL250 engine?

You need to and also use its two pulsing coil pickups instead of the newer single coil pickup (found on the EL250B/E and EX250F's) if you are using the analog 1986-1987 igniter.


Nice to see another of these early model being saved. I got two of them myself.
I swapped over the stator from the ex250e.

Could you explain that a bit more? I'm using the ex250e coils and one side has spark its just the other side has no power going to the coil pack. I've swapped coils to see if the other one works, and it does. I just think the igniter isnt fully working. I should be able to look at it some more today.

Wow, that's awesome man. I bet you enjoy them a lot.
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Old May 7th, 2013, 09:00 PM   #30
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Nice bike and nice cars, man, and good luck on the ME.

I have an 86. Love the styling. Very impressive that you have the orig blinkers front and rear. Those are usually the first to go after a drop and then they solder on a two wire front signal instead of the orig three wire. Overall, body work (which is totally irreplaceable and much rarer than the bike itself) looks good.

To my knowledge, the forks are larger on the 250F than the 250E. You'll find that many parts are just 1% different between the two and makes it 100% unusable. Just be aware before you drop 175 on an F thinking you'll have a good parts bike.

good luck.
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Old May 8th, 2013, 01:08 PM   #31
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Nice bike and nice cars, man, and good luck on the ME.

I have an 86. Love the styling. Very impressive that you have the orig blinkers front and rear. Those are usually the first to go after a drop and then they solder on a two wire front signal instead of the orig three wire. Overall, body work (which is totally irreplaceable and much rarer than the bike itself) looks good.

To my knowledge, the forks are larger on the 250F than the 250E. You'll find that many parts are just 1% different between the two and makes it 100% unusable. Just be aware before you drop 175 on an F thinking you'll have a good parts bike.

good luck.
Thanks man

I love the styling too, just something about how its all put together makes it awesome. I have a lot of experience doing fiberglass work so it shouldn't be a problem ffixing some of the cracks on the body work, I also have a paint guy so it should be looking good over the summer time.

Yes, I have been learning here and there about things that are slightly different that don't swap over. Makes ordering parts harder but I'm getting the hang of it.

Only update I have is I bought two new spark plugs and a fully working igniter for cheap, so ill see if that is the problem. Also there is 3 weeks of school left this quarter so ill be slow to update due to cramming for finals.

Everyone have a good day!
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Old May 8th, 2013, 01:21 PM   #32
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I dig that red on white. Classic.

Good work, looking forward to seeing the end result.
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Old May 9th, 2013, 06:57 PM   #33
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I dig that red on white. Classic.

Good work, looking forward to seeing the end result.
thank you! Im liking the white, then seeing pictures of black are swaying me towards black. Im not sure if doing it white would make it too much white with the wheels? or i would need them a different color, or im just crazy. I will probably stick with the white anyways.
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Old May 16th, 2013, 04:46 PM   #34
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Im stuck!

Ive spent awhile going through the no spark the past few days. Ive replaced the Igniter with a known working one, i replaced the pick up coil, the wiring was iffy at best, ive traced wires to see if there are anything broken. Nothing. What am i over looking?

Again im getting spark on the left side of the bike. and nothing on the right side. Both coils are good.

thanks again guys!
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Old May 16th, 2013, 06:54 PM   #35
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also, should i be getting power from the pickup coil if i disconnect it, prob the plug with the other lead to ground, and crank it?
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Old May 23rd, 2013, 09:29 PM   #36
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Anybody have any idea? Taking my safety class next week! Excited for that.
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Old May 24th, 2013, 10:54 AM   #37
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Anybody have any idea? Taking my safety class next week! Excited for that.
Engine not running, ignition on. Do you have power at each side of the coil?
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Old May 24th, 2013, 11:23 AM   #38
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Engine not running, ignition on. Do you have power at each side of the coil?

Do not have power to the right side coil. Have a working igniter and replaced the pick up coil. Haven't found out why I haven't been getting power to tthat side yet.
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Old May 24th, 2013, 01:40 PM   #39
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Quote:
Originally Posted by marines2060 View Post
Do not have power to the right side coil. Have a working igniter and replaced the pick up coil. Haven't found out why I haven't been getting power to tthat side yet.

The red wires on each coil are the positve wires coming off the kill switch. If you have power at one coil that tells me the switch is ok. The two red wires are spliced together in the harness somewhere.So, if you take a jumper wire and jump power temporarily from the battery positive to the red wire of the coil that has no power then crank the engine and check spark then youll confirm the faulty wiring.
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Old May 24th, 2013, 02:00 PM   #40
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